Lesson 1, Introduction to Lean Six Sigma

Question 1

DMAIC

Answer 1

Define, Measure, Analyze, Improve, and Control

Question 2

Five key principles of Lean (Womack)

Answer 2

1. Define value add and non-value add
2. Map the value stream
3. Establish process flow
4. Shift from push to pull systems
5. Strive for perfection / zero defects

Question 3

Six Sigma Goals

Answer 3

• Reduce variation related to the variation within process output (Y) caused by the input or process variables (X)
• Reduce variation toward customer target and specifications
• Reduce variation by eliminating waste.
• Increase customer satisfaction
• Reduce costs
• increase product quality.

Question 4

Customer satisfaction can be achieved by: (Example Education)

Answer 4

1. Conformance to Specification (Crosby)
   (Provide education that connects with the business level)
2. Value
   (Quality of lessons is high.)
3. Fitness for Use
   (Content matches with industry needs)
4. Support
   (Gives better opportunities in your professional career)
5. Psychological Impressions
   (The feeling you have to study)

Question 5

How is the progress monitored?

Answer 5

1. Define, (define the opportunity from both business and customer perspectives)
2. Measure, (Understand the process and its performance)
3. Analyze, (Search the key factors (critical X’s) that have the biggest impact on process performance and determine the root causes)
4. Improve, (Develop improvement solutions for the critical X’s
5. Control, (implement the solution and control plan.)

Question 6

critical enablers on how the progress is monitored.

Answer 6

Project selection - (is it worthwhile, feasible, and the likelihood of success)
Project sponsorship - (Do we have enough people and/or time, is there someone who provides the resources)
Tollgate reviews - (Points in the project where you reflect)

Question 7

Project selection

Answer 7

Feasible
business results with limited investments
data availability
high probability of success

Question 8

Lean six sigma roles

Answer 8

Yellow belts
Green belts
Black belts
Master black belts
project sponsors
Deployment manager

Question 9

4 ways to express process quality

Answer 9

1. DPMO - Defects per Million Opportunities
2. Yield % - Number of good products relative to the number of produced products
3. CpK - Process capability relative to product specifications
4. σ - level - Statistical measure of a process’s ability to customer requirements

Question 10

CTQ

Answer 10

Critical to Quality, what is critical to maintaining quality